brake maintenance, penny wise, pound foolish?

If this post prevents one other forum member from making this mistake it will be worth it. brakes have been rubbing and got some confidence to 'ave a go at cleaning them, 2007 SD (plenty of pad left )removed spring clips, pads and start to go to town with a soapy toothbrush around pistons. Then I couldn't help myself and wanted to see the pistons in action (system still pressurized). 3 out of 4 pistons progressively move toward the midline. One is not.

Slow cautious pumping turns to more desperate pumping (I'm sure you all know where this is going) Still talking about the brake lever. btw loving the nekkid thread!

Focusing on the non - moving piston, before i know it the opposing piston has left its bore and dot 5.1 is dripping onto the garage floor. Brake lever now has zero resistance.
I've been told by a wise man that " if one finds himself in a hole, one should stop digging!" and that 's where I am now.

Your thoughts on what happened and where to go from here (Could it be the anthracite colour?)

I thank all in advance for assistance. This site has made owning a superduke easier and much more gratifying.

Well, since you've done it, might as well take all pistons out and clean the caliper bores. remove seals and clean pistons and reassemble. I think you'll notice all pistons will move much more freely.

thank you Lowrance, for $26.41 I can get a set of 4 rubber seals. Seems like a steep learning curve to rebuild the caliper though. I'm not sure I'm up to taking my life in my own hands on this crucial job though. Looked though the spare parts manual and no specific tool is mentioned as a "Brake piston puller outer" I guess i could waste good brake fluid by rebleeding and then using hydralics to push them out of the bore again? I also checked the repair manual for this and came up with nada. can anyone assist with the finer points of doing this? Should we take an informal poll? (Should Numb - nutz attempt rebuilding his own front brake calipers?)

Here ya go dude -

viewtopic.php?f=18&t=12626

You probaby only need to put it back together, you have basically just pushed the piston out and all that really needs doing is pushing back in again as long as the seal is not damaged but I doubt it is.

Each piston has two seals.

Bleeding the front brake is not hard if you have a big syringe and some pipe.

Ahh yes. thanks Bash and Superdan. Since there is no KTM shoppe locally, will try it and do the right side first, test, then if I'm still alive, the left. Cheers. will be careful not to fill resevoir too high.